Okay, so I got this (Powertrax locker for a Ford 8.8):


the other day. I'm still working on seeing if I can get it to fit into a Mitsu carrier.

Question: How easy/practical/possible is it to machine something like this? I'd guess this is some pretty hard steel and not that 'easy' to machine. Any thoughts (i.e., do I need to find a machine shop w/ specialized equipment, should any old shop be able to do it)?

TIA,

-Jim

I'm no pro but just to get you started - it was obviously machined in order to make it right? that's not just a cast piece <img src="/forums/images/graemlins/kewl.gif" alt="" />

Yeah, but it was probably machined before it was heat-treated. (I'd have to believe the heat-treating made it much tougher to machine). At least I think it was heat-treated... <img src="/forums/images/graemlins/confused.gif" alt="" />

Oh yeah, one more thing: any idea if this is surface hardened or hardened throughout the whole piece?

Well Jim, I'm not sure that I can answer your questions, but I'll try. The unit is most certainly hardened but I'm not sure just what process was used. It is also machined as a unit, and that is why it is marked the way it is. I "think" it could be annealed for machineing but without knowing the precess I can't be sure. Any machining on a hardened part is going to almost certainly be done with a grinder and a controlled lube source and not going to be easy, or cheap. Again, not to throw rocks <img src="/forums/images/graemlins/smile.gif" alt="" />..but I think that you are perhaps better just playing with the Mitsu stuff, rather then trying to re-invent the unit. If I can help, just ask. <img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/notooth.gif" alt="" /> <img src="/forums/images/graemlins/smile.gif" alt="" />
Kary

That's kinda what I was afraid of <img src="/forums/images/graemlins/frown.gif" alt="" />. I'm not too surprised to hear it'd have to be done w/ a grinder (as opposed to a 'regular' cutting tool). As far as annealing and then re-heat-treating, that sounds like way too much money.

Back on eBay the locker goes. I might put the whole truck on there too...

I would be surprised if it was heat treated so hard that you can't machine it. That would make it too brittle.
Now the parts inside may be hardened. It is easy to find out. Take it to a heat treater and have them Rockwell test the surface hardness. They probably won't even charge you.
Bob Shaw

Step 1: Measure the part and find out if it can be modified to fit. If the answer is no you can stop.

If yes (and I can help with that part) you may need to do some investigation.

First thing would be to try and find out what it is made of. See if you can find any casting marks. That would be a good indicator that its cast iron (or cast steel).

The black finish is probably Parkerizing (or an equivalent). This has some anti wear properties but is also used for appearance and corrosion resistance. A quick hardness test is to run a file across a surface that is not important. If you can file it you can easily machine it.

It is also easily repaired. Most cam grinders big and small have this process. A call around to various shops may find on that is helpful. You can probably leave it off and not have a problem.

Some hardened surfaces can be machined with a carbide cutter and plenty of coolant I have done this a number of times. You can cut very hard surfaces if you use liquid nitrogen for a coolant directly on the cutting insert. That is probably out of reach of most of usà

Options for dealing with a hardened surface are put the parts in an oven and anneal them, make the changes you need and send them out for nitriding.

You can call the manufacture and ask to speak to a design engineer. Tell them you need to modify certain dimension for a special project and can they tell you the material used and the surface treatment used on the part.

If they have an open mind and donÆt think you are a competitor they may help you out. If they are worried about information disclosure, offer to sign a NDA. Stating you wont tell anyone what they tell you.

As Bob mentioned get a Rockwell hardness test. Look to see if various areas are selectively hardened. This is common with flame hardening and induction hardening. The clutch dogs and wear surfaces may be harder than the rest of the part.

Most times you want the surface ahrd for wear resistance and the under metal soft for toughness. This is how gear teeth are done.

There is so much surface area on those teeth they may not be critical. I would try the file test on them easy cut = soft. Bounces off and leaves a mark on the file = hard.

Good luck,

Kevin

Bob and Kevin,

Thanks for the replies! I realize it can be machined, somehow, some way. The question is: at what cost? It really seems the cost would be higher than it's worth (i.e., might as well just spend the $ for an ARB, use a limited slip instead of a locker or sell the truck. I'm leaning toward the latter).

Kevin,

Aside from the difficulty in machining, I believe the answer is 'yes'. Although, I think a Ford 9" locker might be a better choice. There may be a way to make it fit so that the locker wouldn't have to be machined (a sleeve would have to be made to make up for the size difference). The Montero side gear is on the left; the Ford locker coupler is on the right:


Obviously, the part of the Montero side gear that goes into the carrier is bigger than on the Ford.

The couplers of the 8.8 locker are too wide (side-to-side) which is why they'd have to be machined.

PM me or post a reply if you're interested in details.